Tabletop for Outdoor Use Having Metal Frame

ABSTRACT

A tabletop for use on an outdoor table is disclosed. A metal frame having at least one horizontally oriented transverse member defines the general shape of the tabletop. A fiber fabric layer is affixed to the top of the transverse member. A decorative layer comprising a plurality of spaced apart decorative elements provides the outer surface of the table top. A mesh layer is positioned between the fiber fabric layer and the decorative layer. The elements are adhered together by a binder comprised of adhesive material. The binder is interposed between and contacting the at least one transverse member and the decorative layer so that the layers of fiber fabric and mesh are embedded within the binder and the decorative layer is fixedly adhered to the at least one horizontally oriented transverse member.

FIELD OF INVENTION

Embodiments of the present invention relate generally to a tabletop, andmore particularly to a tabletop for outdoor use that is reinforced witha metal frame.

BACKGROUND OF THE INVENTION

Tabletops are generally made of wood. However, wood tabletops are oftensubject to deterioration due to acidic, basic, air or water conditionsover time. Therefore, tabletops, especially those for outdoor uses, arenow made of other materials such as plastics, metals, or compositematerials.

Since plastic materials are light weight and can more readily withstandharsh environmental conditions, the majority of tabletops for outdooruse are currently made of plastic materials. If such lighter materialsare employed, sufficient supporting strength and rigidity cannot beachieved without additional structure. Some designs include a baseplate, with the object of having sufficient strength to avoid warping,giving, or bending, especially for larger tables. However, tabletopsmade of bulky plastic materials and large supporting plates are tooheavy in weight, especially for portable tables. It is still necessary,however, for the tables to provide sufficient strength and rigidity tosupport normal activities without warping or bending.

Tables have been made with cement board as a base plate. These tablestypically include a magnesium silicate plate including magnesium oxide(MgO) as the main component, or other similar composite plate. The tabletop made of such material remains reasonably flat, but only for smallersize tables, up to about 20 or 30 inches in diameter. If the plate usedin larger tables having diameters of 42 inches and up to 80 inches for arectangular table top, the table warps in extreme temperatures. This isbecause the poly resin included as a binder or media used to adhere thesupport plate to the stone layer expands and contracts based ontemperature gradients. Resin expands when the temperature increases andcontracts when the temperature drops. The volume of the resin varieswith the temperature change. If the base plate which is adhered to theresin shows a certain level of flexibility, it tends to bend with resin.The whole table then warps.

Some table tops have been made using a metal plate, which is strong andtough to resist bending, but adds significant weight to the table. Inaddition, the metal plate usually does not have good adhesion with theresin and may separate from the resin easily. Glue has been used toattempt to keep the plate adhered to the stone top. In some cases, whena much stronger table is desired, a single or double frame underneath ofthe plate may be used to provide additional strength. This only adds tothe problem of the heavy weight. Such tables are a burden to ship,deliver, and move.

The type of binder used for outdoor table tops may also be a factor inwarping. Polyester resin is a frequently used binder due to its cost.The drawback of polyester resin is its thermal expansion and contractionproperties. The resin tends to expand and/or contract significantly withchanges in temperature causing it to change volume. If the frame doesnot provide sufficient resistance to bending, the whole table will warp.If the deformation and temperature cycling is frequent, the table mayeven crack.

Thus, there is a need for relatively low cost tabletops with sufficientsupport strength to resist warping, and sufficiently light weight to beportable.

SUMMARY OF THE INVENTION

Embodiments of the invention relate to a tabletop for use on an outdoortable that includes a metal supporting frame having at least one portionthat forms a substantially horizontally oriented transverse member. Thetabletop further includes a layer of horizontally oriented fiber fabricaffixed to the top of the supporting frame transverse member by adhesivematerial, substantially horizontal decorative layer positioned above andproximate to the transverse member, and a layer of horizontally orientedfiber mesh affixed to the bottom of the decorative layer by adhesivematerial, a substantially horizontal layer of adhesive materialinterposed between and contacting the at least one horizontally orientedtransverse member and the horizontal decorative layer so that the layersof fiber fabric or fiber mesh are embedded within the adhesive material.The decorative layer is adhered to the at least one horizontallyoriented transverse member.

The adhesive material may be a binder material, such as resin formed ofan unsaturated polyester resin, a vinyl ester resin, or an epoxy resin.The decorative layer typically resembles stone and is formed of one ormore of stone, marble, clay, slate, granite, tile, ceramic, orporcelain. The supporting frame may be formed of aluminum, iron, orsteel and the fiber fabric may have a random orientation or have a wovenpattern. A metal mesh may be used in place of the fiber fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tabletop frame for one embodiment ofthe present invention.

FIGS. 2A-2D illustrates exemplary shapes of the tabletop frame forvarious embodiments of the invention.

FIG. 3 is a cross-sectional view of a tabletop for one embodiment of thepresent invention.

FIG. 4 is a cross-sectional view of a tabletop for another embodiment ofthe present invention.

FIG. 5 is a data flow diagram describing a method of creating a tabletopaccording to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention provide a tabletop for outdoor usethat is light weight while maintaining support strength and rigidity.The tabletop has sufficient strength in the adhesion among itscomponents to resist deformation or warping. Further, the tabletop isresistant to common outdoor environmental conditions, such as acidic,basic, air, and wet conditions.

Referring to FIG. 1, a perspective view of a tabletop frame 20 of anembodiment of the present invention is illustrated. The metal frame 20includes at least one horizontally oriented transverse member 21. A rim22 is coupled with and surrounds the at least one horizontally orientedtransverse member(s) 21 defining the shape of the tabletop. In thepresent illustration, the rim 22 defines the shape of a circle and thereare four horizontally oriented transverse member(s) 21 that extend fromthe rim 22 at ninety degree intervals and meet in the center of thedefined circle. The horizontally oriented transverse member(s) 21coupled with the rim 22 add to the overall stability, strength, andrigidity of the metal frame 20.

FIGS. 2A-2D illustrate several other exemplary shapes of the metal frame20 that may be used with various sized tabletops.

FIG. 2A shows a tabletop frame 20 having an outer rim 22 also in theshape of a circle. In this embodiment illustration, there is aconcentric circular horizontally oriented transverse member 21 a that isin the same horizontal plane as but smaller than rim 22. Furtherillustrated are four horizontally oriented transverse member(s) 21 thatextend from the rim 22 at ninety degree intervals and meet the innercircular horizontally oriented transverse member 21 a at ninety degreeintervals. Again, the horizontally oriented transverse member(s) 21 and21 a coupled with the rim 22 add to the overall stability, strength, andrigidity of the metal frame 20.

FIG. 2B shows a tabletop frame 20 having an outer rim 22 also in theshape of a circle. In this embodiment illustration, there is arectangular shaped horizontally oriented transverse member 21 b that isin the same horizontal plane as but smaller than rim 22. Both the rim 22and the rectangular shaped horizontally oriented transverse member 21 bshare the same center point. Further illustrated are four horizontallyoriented transverse member(s) 21 that extend from the rim 22 at ninetydegree intervals and meet the inner rectangular shaped horizontallyoriented transverse member 21 b such that each bisects one side of therectangular shaped horizontally oriented transverse member 21 b. Again,the horizontally oriented transverse member(s) 21 and 21 b coupled withthe rim 22 add to the overall stability, strength, and rigidity of themetal frame 20.

FIG. 2C shows a tabletop frame 20 having a rectangular shaped rim 22 a-bwith the horizontally oriented transverse member(s) 21 c-e in aparticular configuration. Such configurations become favorable when asthe overall size of the tabletop gets larger. The additionalhorizontally oriented transverse member(s) 21 c-e coupled with the rim22 a-b add to the overall stability, strength, and rigidity of the metalframe 20. In this particular example configuration, a first set ofhorizontally oriented transverse member(s) 21 c extend perpendicularlyfrom the long side of the rectangular rim 22 a and terminate at theopposite side of the rectangular rim 22 a. A second set of horizontallyoriented transverse member(s) 21 d extend perpendicularly from the shortsides of the rectangular rim 22 b and terminate when they encounter oneof the horizontally oriented transverse member(s) 21 c of the first set.A third set of horizontally oriented transverse member(s) 21 e extendperpendicularly between two of the first set of horizontally orientedtransverse member(s) 21 c. Again, the horizontally oriented transversemember(s) 21 c-e and 21 b coupled with the rim 22 a-b add to the overallstability, strength, and rigidity of the metal frame 20.

FIG. 2D shows a tabletop frame 20 having a rectangular shape withrounded corners with the horizontally oriented transverse members 21 atvarious acute and obtuse angles to each other and the outer rim 22.Again, the horizontally oriented transverse member(s) 21 coupled withthe rim 22 add to the overall stability, strength, and rigidity of themetal frame 20.

The metal frame 20 helps to keep the table from warping and providesadditional strength. The metal frame 20 may be formed of aluminum, iron,steel, or similar metals or alloys. The metal frame 20 also provides aconvenient means of connecting with the tabletop with the table legs.

Several exemplary arrangements of transverse members 21 and rims 22 havebeen illustrated in FIGS. 1 and 2A-D. The arrangements need not be solimited, however, with respect to the present invention. The transversemembers 21 may be arranged in any manner, so long as they providesufficient support for the tabletop 10. Rim 22, or additional transversemembers 21 may define any shape desired for the perimeter of a tabletop.Spaces formed between various transverse members 21 and rim 22 may beopen, reinforced with an inner structure, or may comprise some otherdesired structure. Any number of transverse members 21 may be usedwithin the scope of the present invention.

Tabletops according to embodiments of the present invention may be usedfor outdoor use, and are often used in conjunction with an umbrella toprovide shade or protection of individuals from rain or sun. In oneembodiment of the invention, the center of the tabletop 10 can includean intersection of the transverse members 21 that define a hole for anumbrella. Such an umbrella hole is optional, and mostly suitable fordining tables, bar tables, conference tables, or large tables. Smallertables, such as balcony tables, coffee tables, side tables, or endtables, may not require an umbrella.

FIG. 3 is a cross-sectional view of an embodiment of the presentinvention. As shown, a tabletop 10 is comprised of a metal frame 20covered by a fiber fabric layer 25. The fiber fabric layer 25 is adheredto the metal frame 20 by a binder 30, such as a resin or other adhesivematerial. Typically, the binder 30 soaks through the fiber fabric layer25 and adheres to the metal frame 20. On top of the fiber fabric layer25, there is a mesh layer 28 covered by a decorative layer 40. Thebinder 30 is also used to adhere the decorative layer 40 to the meshlayer 28.

A sufficient amount of binder 30 surrounds and fills the gaps betweenindividual spaced apart elements/pieces 45 of the decorative layer 40.The use of individual spaced apart decorative elements/pieces 45enhances the bond with binder 30. For instance, if a single piecedecorative layer 40 were to be used, there would be a likelihood ofseparation from binder 30 due to variation in thermal expansion orcontraction. By using a plurality of spaced apart decorative elements45, however, the thermal expansion or contraction effect issubstantially reduced. Binder 30 saturates mesh layer 28 affixing it todecorative layer 40. The binder 30 further saturates and adheres thefiber fabric layer 25 to the metal frame 20

The fiber fabric layer 25 and mesh layer 28 used in the embodiments ofthe present invention can be embedded into the binder 30. The primaryfunction of the mesh layer 28 is to anchor the decorative elements 45 ofthe decorative layer 40 and to improve the strength of the adhesionbetween the binder 30 and the decorative layer 40. The loose weave ofthe mesh layer 28 permits binder 30 to freely surround and penetratethrough the mesh layer 28 to embed the layer. The mesh layer 28 alsolowers the brittleness of the binder 30, simultaneously enhancing thetensile strength properties of the binder 30. The loose weave is alsoflexible, which can avoid or reduce cracking or chipping of the binder30, further preventing the whole table top from warping and cracking.

The mesh layer 28 typically may have openings or spaces of about 10 mmby 15 mm, although larger or smaller dimensions may be used as known tothose of ordinary skill in the art, depending in part on the size ofelements 45. In general, when a woven opening is not generally visible,the material would be considered fabric.

The fiber fabric 25 can be a glass fiber “random” matting, in which thefibers are oriented generally randomly. This type of matting gives greatstrength in all directions. A second type of fiber fabric 25, known as“woven” matting could also be used. Such a fiber fabric 25 is tightlywoven in a similar manner as a cotton sheet. The fiber fabric 25 tendsto provide greater vertical support strength and rigidity in thatdeformation stress is randomized along the various fibers. Duringtemperature cycling, the binder 30 expands and contracts at a differentrate from the metal frame. This can cause de-lamination of supportlayers. Even with less planar metal frames, the variation in thermalexpansion and contraction properties may cause the binder 30 to separatefrom the metal frame 20 in extreme conditions. By adding a layer offiber fabric 25, the deformation stress tends to be more randomized andcontrolled. Further, when the fiber fabric 25 is embedded in curedbinder 30, it binds well to transverse members 21 and provides enhancedvertical support strength to a table.

The mesh layer 28 is typically formed from nylon thread, although othernatural or synthetic fibers may be used. For example, the mesh layer 28can be fiber glass formed of continuous fibers, such as those used inelectrical insulation, cement, or plastics reinforcement. The mesh layer28 often has the appearance of thin netting. The mesh layer 28 typicallyhas a density of about 300 g/m². Mineral fibers may also be used. Duringassembly, the mesh layer 28 provides temporary fixing to hold thedecorative elements 45 in position. Great strength is not needed at thatstep, but it is important that the resin is able to penetrate throughthe openings in the mesh layer 28 onto the decorative elements 45 belowto ensure good adhesion.

In some embodiments, the mesh layer 28 or fiber fabric layer 25 may alsobe replaced by a layer of metal screen (not shown). The metal screenwould typically be attached to the metal frame 20 by standard metalfasteners, such as screws, bolts, rivets, or the like. Of course, ametal screen replacing mesh layer 28 would generally be required toprovide a desired level of vertical support. A variety of metals may beused, such as aluminum, steel, iron, or alloys thereof. Preferably, thescreen would be sufficiently flexible to lie flat within the binder 30.Otherwise, portions of the screen might protrude from the binder 30,causing irregularities or exposed screen, which might require grindingand/or painting.

The tabletop 10 may further comprise a decorative layer 40 adhered tothe mesh layer 28 with the binder 30. The decorative layer 40 willtypically contain a decorative design. For example, the decorative layer40 may be configured to resemble stone or similar materials. Theparticular design chosen is not a limiting feature of the presentinvention. The decorative layer 40 may include one or more of stone,marble, clay, slate, granite, tile, ceramic, porcelain or a decorativedesign that resembles stone. The decorative layer 40 may include one ormore stone material, including marble, clay, slate, or granite, or mayinclude tile, ceramic, porcelain or a decorative design that resemblesstone. The decorative layer 40 may include a mixture of stone powder,coloring powder, and calcium powder to resemble stone.

A decorative layer 40 is shown adhered to the mesh layer 28. Thedecorative layer 40 is formed of individual elements 45 having gapstherein, as shown. In an embodiment shown in FIG. 4, the top and sidepieces of the decorative layer 40 are separate, and a gap is shownbetween pieces of the decorative layer 40 on the top surface of thetable.

Binders 30 that may be used with the present invention includeunsaturated polyester resin, vinyl ester resin, epoxy resin, or similarsuch resins. The binder 30 may include a pigment to enhance its color.In one binder 30 example, 1 Kg of resin is added to 7-15 g of anadhesive formed of calcium powder and color pigment. Alternatively, wecan also use vinyl ester resin and epoxy resin. Fine sand may be addedto the resin if a rough texture is desired. A curing agent may be addedto speed the drying time of the resin.

FIG. 5 is a data flow diagram describing a method of creating a tabletopaccording to an embodiment of the present invention. The first step isto place a layer of fiber fabric on top of a metal frame that definesthe outline of a tabletop 50. Next, cover the layer of fiber fabric witha binder such that it soaks through the layer of fiber fabric andadheres the layer of fiber fabric to the metal frame forming ametal-fiber reinforced structure 52. A decorative layer is placed facedown and covered with a mesh layer. Some binder is poured/spread atopthe mesh layer to provide a temporary bond between the decorative layerand the mesh layer 54. More binder is then added to substantiallycompletely impregnate the decorative and mesh layers creating a binderlayer 56. The binder layer is then smoothed out. The metal-fiberreinforced structure is then placed atop the binder layer allowing thebinder layer to further soak through the metal-fiber reinforcedstructure and cure 58. The result is a finished tabletop.

It is to be understood that the invention is not to be limited to theexact configuration as illustrated and described herein. Accordingly,all expedient modifications readily attainable by one of ordinary skillin the art from the disclosure set forth herein, or by routineexperimentation therefrom, are deemed to be within the spirit and scopeof the invention as defined by the appended claims.

1. A tabletop for use on an outdoor table comprising: a metal framehaving at least one horizontally oriented transverse member wherein themetal frame defines the general shape of the tabletop; a horizontallyoriented fiber fabric layer affixed to the top of the horizontallyoriented transverse member; a substantially horizontal decorative layer,wherein the decorative layer comprises a plurality of spaced apartdecorative elements; a horizontally oriented mesh layer positionedbetween the fiber fabric layer and the decorative layer; and a bindercomprised of adhesive material, said binder interposed between andcontacting the at least one horizontally oriented transverse member andthe horizontal decorative layer so that the layers of fiber fabric andmesh are embedded within the binder and the decorative layer is fixedlyadhered to the at least one horizontally oriented transverse member. 2.The tabletop of claim 1, wherein the binder is a resin.
 3. The tabletopof claim 2, wherein the resin is one or more of an unsaturated polyesterresin, a vinyl ester resin, or an epoxy resin.
 4. The tabletop of claim1, wherein the decorative layer resembles stone.
 5. The tabletop ofclaim 4, wherein the decorative elements comprise one or more of stone,marble, clay, slate, granite, tile, ceramic, or porcelain.
 6. Thetabletop of claim 1, wherein the metal frame is formed of one or more ofaluminum, iron, or steel.
 7. The tabletop of claim 1, wherein the fibersin the fiber fabric layer have a random orientation.
 8. The tabletop ofclaim 1, wherein the mesh layer is comprised of fiber glass.
 9. Thetabletop of claim 1, wherein the mesh layer is comprised of nylonthread.
 10. The tabletop of claim 1, wherein the mesh layer is comprisedof a metal screen.
 11. A method of forming a tabletop comprising:placing a layer of fiber fabric on top of a metal frame that defines theoutline of a tabletop; substantially covering the layer of fiber fabricwith a binder such that it soaks through the layer of fiber fabric andadheres the layer of fiber fabric to the metal frame forming ametal-fiber reinforced structure; placing a decorative layer face downand covering the decorative layer with a mesh layer; adding binder ontop of the mesh layer to impregnate and bond the decorative layer andmesh layer together creating a binder layer; smoothing out the binderlayer; and placing the metal-fiber reinforced structure onto the binderlayer allowing the binder layer to further soak through the fiber layerand cure.
 12. The method of claim 11, wherein the binder is a resin. 13.The method of claim 12, wherein the resin is one or more of anunsaturated polyester resin, a vinyl ester resin, or an epoxy resin. 14.The method of claim 11, wherein the decorative layer resembles stone.15. The method of claim 14, wherein the decorative elements comprise oneor more of stone, marble, clay, slate, granite, tile, ceramic, orporcelain.
 16. The method of claim 11, wherein the metal frame is formedof one or more of aluminum, iron, or steel.
 17. The method of claim 11,wherein the fibers in the fiber fabric layer have a random orientation.18. The method of claim 11, wherein the mesh layer is comprised of fiberglass.
 19. The method of claim 11, wherein the mesh layer is comprisedof nylon thread.
 20. The method of claim 11, wherein the mesh layer iscomprised of a metal screen.